Optical waveguide module system and method

ABSTRACT

The present disclosure relates to systems and methods for optically connecting circuit elements and optical fiber systems. In one embodiment, an optical waveguide module includes an optical light guide having opposite first and second planar surfaces extending between a first side edge and a second side edge. The optical light guide can be configured with a substrate supporting one or more optical pathways extending between the first and second side edges. The waveguide module can further include one or more first and second edge connectors, each of which has an adapter port and a first alignment slot opposite the adapter port. The alignment slots extend over the first and second planar surfaces at the first and second side edges to align the adapter ports with the one or more optical pathways in a first direction.

RELATED APPLICATIONS

This application is a Divisional Application of U.S. patent applicationSer. No. 14/775,035, filed on 11 Sep. 2015, which is a National Stage ofPCT International Patent application No. PCT/US2014/024657, filed on 12Mar. 2014 and claims priority to U.S. Patent Application Ser. No.61/777,654, filed on 12 Mar. 2013, and U.S. Patent Application Ser. No.61/878,388, filed on 16 Sep. 2013 and which applications areincorporated here by reference. To the extent appropriate, a claim ofpriority is made to each of the above disclosed applications.

BACKGROUND

The present invention relates to systems and methods for opticallyconnecting circuit elements in optical fiber systems. In some fiberoptic systems, fiber optic cables are connected to one another throughsplices, or through connection systems including two connectors held inalignment by an adapter. Various connector and adapter formats are knownincluding SC, LC, and MPO. SC and LC are single fiber formats. MPOconnection systems are multiple fiber formats. There is a continuingneed for connection systems for connecting fiber optic equipment.

SUMMARY

Optical waveguide modules are disclosed. In one embodiment, an opticalwaveguide module includes an optical light guide having opposite firstand second planar surfaces extending between a first side edge and asecond side edge. The optical light guide can be configured to includeone or more optical pathways extending between the first and second sideedges. The waveguide module can further include one or more first edgeconnectors, each of which has a first adapter port and a first alignmentslot opposite the first adapter port. The first alignment slot extendsover the optical light guide first and second planar surfaces at thefirst side edge to align the first adapter port with the one or moreoptical pathways in a first direction. The waveguide module can alsoinclude one or more second edge connectors, each of which has a secondadapter port and a second alignment slot opposite the second adapterport wherein the second alignment slot extends over the optical lightguide first and second planar surfaces at the second side edge to alignthe second adapter port with the one or more optical pathways in thefirst direction.

In one embodiment, the edge connectors include a first sleeve receivedwithin a cavity of a first body wherein the first body has a firstadapter port. As presented, the first sleeve has a first alignment slotopposite the first adapter port, and the first alignment slot extendsover the optical light guide first and second planar surfaces at thefirst side edge to align the first adapter port with the one or moreoptical pathways in the first direction. Likewise, the second edgeconnectors each have a second sleeve received within a cavity of asecond body wherein the second body has a second adapter port. Thesecond sleeve has a second alignment slot opposite the second adapterport. Also, the first alignment slot extends over the optical lightguide first and second planar surfaces at the second side edge to alignthe second adapter port with the one or more optical pathways in thefirst direction.

In one embodiment, the optical waveguide module includes a first andsecond optical light guide. The first optical light guide can includefirst and second opposite surfaces extending between first and secondopposite side edges wherein the optical light guide includes one or morefirst optical pathways extending between the first and second sideedges. The second optical light guide can include first and secondopposite surfaces extending between first and second opposite side edgeswherein the second optical light guide supports one or more secondoptical pathways extending between the first and second side edges. Afirst edge coupler aligns the one or more first optical pathways of thefirst optical light guide with the one or more second optical pathwaysof the second optical light guide. In one embodiment, the first edgecoupler has a first alignment slot and a second alignment slot oppositethe first alignment slot. The first alignment slot extends over thefirst optical light guide first and second planar surfaces at the firstside edge to align the first edge coupler with the one or more firstoptical pathways in a first direction. The second alignment slot extendsover the second optical light guide first and second planar surfaces atthe first side edge to align the first edge coupler with the one or moresecond optical pathways in the first direction.

Optical light guide edge protection features are provided in someexamples. One example is in the form of an index matching film. Anotherexample of a waveguide edge protection feature is in the form of aspaced end face.

Each of the described embodiments herein for the side edge connectorsincludes passive alignment features (e.g. alignment slots, tabs,notches, and protrusions), meaning that optical alignment betweencomponents is obtained by the passive alignment features withoutrequiring measuring and adjusting the positions of the components afteran initial alignment process. Furthermore, the fiber optic connectors(e.g. MPO, LC, etc.) and the disclosed side edge connectors can beeasily and repeatedly connected and disconnected from each other withouta loss in alignment and without requiring additional alignment steps.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of an assembled and connected opticalwaveguide module having features that are examples of aspects inaccordance with the principles of the present disclosure.

FIG. 2 shows a cross-sectional side view of the optical waveguide moduleshown in FIG. 1.

FIG. 3 shows a perspective view of the assembled optical waveguidemodule of FIG. 1 that is disconnected from the shown connectors.

FIG. 4 shows a cross-sectional side view of the optical waveguide moduleshown in FIG. 3.

FIG. 5 is an exploded perspective view of the optical waveguide moduleshown in FIG. 1.

FIG. 6 is a cross-sectional side view of the optical waveguide moduleshown in FIG. 5.

FIG. 7 shows a cross-sectional side view of an edge connector usablewith the optical waveguide module shown in FIG. 1.

FIG. 8 shows a cross-sectional schematic view of a planar optical lightguide usable with the optical waveguide module shown in FIG. 1.

FIG. 9 shows a perspective view of a second embodiment of an assembledand connected optical waveguide module having features that are examplesof aspects in accordance with the principles of the present disclosure.

FIG. 10 shows a cross-sectional side view of the optical waveguidemodule shown in FIG. 9.

FIG. 11 shows a side view of an edge connector usable with the opticalwaveguide module shown in FIG. 9.

FIG. 12 shows a partial exploded top view of the optical waveguidemodule shown in FIG. 9.

FIG. 13 shows a perspective view of a third embodiment of an assembledand connected optical waveguide module having features that are examplesof aspects in accordance with the principles of the present disclosure.

FIG. 14 shows an exploded top view of a center portion of the waveguidemodule shown in FIG. 13.

FIG. 15 shows a top view of the center portion of the waveguide moduleshown in FIG. 13.

FIG. 16 shows a cross-sectional side view of the center portion of thewaveguide module shown in FIG. 13.

FIG. 17 shows a cross-sectional side view of a side edge connector ofthe waveguide module shown in FIG. 13.

FIG. 18 shows a fourth embodiment of an assembled and connected opticalwaveguide module having features that are examples of aspects inaccordance with the principles of the present disclosure.

FIG. 19 is an exploded perspective view of the optical waveguide moduleshown in FIG. 18.

FIG. 20 shows a pair of the optical waveguide modules shown in FIG. 18connected to each other.

FIG. 21 shows a perspective view of a fifth embodiment of an assembledand connected optical waveguide module having features that are examplesof aspects in accordance with the principles of the present disclosure.

FIG. 22 shows an exploded perspective view of the optical waveguidemodule of FIG. 21.

FIG. 23 shows an exploded cross-sectional side view of one end of theoptical waveguide module of FIG. 21.

FIG. 24 shows an exploded perspective view of a portion of one end ofthe optical waveguide modules of FIG. 21, FIG. 32, and FIG. 43.

FIG. 25 shows a perspective view of a portion of one end of the opticalwaveguide modules of FIG. 21, FIG. 32, and FIG. 43 in an assembledstate.

FIG. 26 shows a cross-sectional side view of one end of the opticalwaveguide modules of FIG. 21, FIG. 32, and FIG. 43 in an assembledstate.

FIG. 27 shows an enlarged cross-sectional side view of a portion of theoptical waveguide module of FIG. 26.

FIG. 28 shows a first perspective view of a sleeve that is part of theoptical waveguide modules shown in FIG. 21, FIG. 32, and FIG. 43.

FIG. 29 is a second perspective view of the sleeve shown in FIG. 28.

FIG. 30 is a cross-sectional side view of the sleeve shown in FIG. 28.

FIG. 31 is a cross-sectional top view of the sleeve shown in FIG. 28.

FIG. 32 shows a perspective view of a sixth embodiment of an assembledoptical waveguide module having features that are examples of aspects inaccordance with the principles of the present disclosure.

FIG. 33 shows an exploded perspective view of the optical waveguidemodule of FIG. 32.

FIG. 34 shows a top view of an optical light guide and connector sleevesof the optical waveguide module of FIG. 32.

FIG. 35 shows a top view of an optical light guide of the opticalwaveguide module of FIG. 32.

FIG. 36 shows a perspective exploded bottom view of one of theconnectors associated with the optical waveguide module of FIG. 32.

FIG. 37 shows a side view of a portion of the optical waveguide of FIG.32.

FIG. 38 shows an exploded side view of a portion of the opticalwaveguide of FIG. 32.

FIG. 39 shows a first perspective view of a sleeve that is part of theoptical waveguide module shown in FIG. 32.

FIG. 40 is a second perspective view of the sleeve shown in FIG. 39.

FIG. 41 is a cross-sectional side view of the sleeve shown in FIG. 39.

FIG. 42 is a cross-sectional top view of the sleeve shown in FIG. 39.

FIG. 43 shows a perspective view of a seventh embodiment of an assembledoptical waveguide module having features that are examples of aspects inaccordance with the principles of the present disclosure.

FIG. 44 shows a perspective view of the sixth embodiment of theassembled optical waveguide module of FIG. 32 inside of an unassembledhousing wherein the connectors are additionally provided with slots forreceiving edges of the housing.

FIG. 45 shows a perspective view of the optical waveguide module of FIG.32 inside of the assembled housing of FIG. 44.

FIG. 46 shows a perspective view of an eighth embodiment of an assembledoptical waveguide module within a housing having features that areexamples of aspects in accordance with the principles of the presentdisclosure.

FIG. 47 shows a perspective view of the assembled optical waveguidemodule of FIG. 46 with a top portion of a housing removed.

FIG. 48 shows a perspective view of the assembled optical waveguidemodule of FIG. 46 removed from the housing.

FIG. 49 shows a perspective view of an optical light guide and connectorsleeves of the optical waveguide module of FIG. 46.

FIG. 50 shows a perspective view of the optical light guide shown inFIG. 49.

FIG. 51 shows a top view of the optical light guide shown in FIG. 49.

FIG. 52 shows a first end view of the optical light guide shown in FIG.49.

FIG. 53 shows a second end view of the optical light guide shown in FIG.49.

FIG. 54 shows a front perspective view of an LC-type connector sleeve ofthe optical waveguide module shown in FIG. 49.

FIG. 55 shows a rear perspective view of the connector shown in FIG. 54.

FIG. 56 shows a bottom view of the connector shown in FIG. 54.

FIG. 57 shows a top view of the connector shown in FIG. 54.

FIG. 58 shows a side view of the connector shown in FIG. 54.

FIG. 59 shows a first end view of the connector shown in FIG. 54.

FIG. 60 shows a second end view of the connector shown in FIG. 54.

FIG. 61 shows a front perspective view of an MPO-type connector sleeveof the optical waveguide module shown in FIG. 49.

FIG. 62 shows a rear perspective view of the connector shown in FIG. 61.

FIG. 63 shows a bottom view of the connector shown in FIG. 61.

FIG. 64 shows a top view of the connector shown in FIG. 61.

FIG. 65 shows a side view of the connector shown in FIG. 61.

FIG. 66 shows a first end view of the connector shown in FIG. 61.

FIG. 67 shows a second end view of the connector shown in FIG. 61.

FIG. 68 shows a perspective view of a ninth embodiment of an assembledoptical waveguide module within a housing having features that areexamples of aspects in accordance with the principles of the presentdisclosure.

FIG. 69 shows a perspective view of the assembled optical waveguidemodule of FIG. 68 with a top portion of a housing removed.

FIG. 70 shows a perspective view of the assembled optical waveguidemodule of FIG. 68 removed from the housing.

FIG. 71 shows a perspective view of an optical light guide and connectorsleeves of the optical waveguide module of FIG. 68.

FIG. 72 shows a perspective view of the optical light guide shown inFIG. 71.

FIG. 73 shows a schematic top view of a sleeve and optical light guidehaving a first alternative shape for the respective protrusions andnotches described for the disclosed embodiments disclosed herein.

FIG. 74 shows a schematic top view of a sleeve and optical light guidehaving a second alternative shape for the respective protrusions andnotches described for the embodiments disclosed herein.

DETAILED DESCRIPTION

Non-limiting and non-exhaustive embodiments are described with referenceto the following figures, which are not necessarily drawn to scale,wherein like reference numerals refer to like parts throughout thevarious views unless otherwise specified.

Referring now to FIGS. 1-7, a first example of an optical waveguidemodule 10 in accordance with the disclosure is presented. The opticalwaveguide module 10 operates as a passive interface with passivealignment features that allow fiber optic connectors, for exampleconnectors 12, 16, to be placed in optical communication with eachother.

As is discussed in greater detail below, this function is achievedthrough the use of a planar optical light guide 20 to which edgeconnectors 50 are attached. The edge connectors 50 each include one ormore adapters to interface with an optical plug, such as LC-duplex,LC-simplex, MPO/MTP, or MT-RJ. Opposite the adapters, the connectors 50will install along the edge of the planar optical light guide 20 andalign to optical pathways 36 present on or within the light guide 20.The optical pathways 36 may be provided with different cross-sectionalshapes, for example round and rectangular cross-sectional shapes. Anoptical signal is transmitted from a first edge connector 50 through anoptical pathway 36 to a second edge connector 50. In one embodiment, theoptical signal will remain passive within the modular unit 10.

As can be seen at FIGS. 2, 44-47, and 68-69 the various disclosedmodules may be provided with a sealed clamshell housing. A housing 91 isshown schematically at FIG. 2, while exemplary housing embodiments 591,791, and 791′ are shown at FIGS. 44-45, 46-57, and 68-69, respectively.As shown, housing 91 has an upper half 92 and a lower half 94, whilehousing 591 likewise has an upper half 592 and a lower half 594. Asshown, upper half 592 and lower half 594 are identically shaped,although this is not necessary. To enable the connectors to extendthrough the housing 591, the upper housing half 592 can be provided withnotched openings 591 a, 593 a and the lower housing half can be likewisebe provided with similar notched openings 591 b, 593 b.

With reference to FIG. 44, it can be seen that the connectors 550 b areprovided with continuous slots 596 a, 596 b that are configured foraccepting and securing the edges of the upper and lower housing halves592, 594, respectively. Connector 550 a is also shown as havingpartially extending slots 598 a, 598 b. These features also help todeflect forces on the substrate caused by the insertion or movement ofthe corresponding fiber optic plug. It is also noted that theconnectors, such as connectors 550 a, 550 b may be provided with upperand lower slots 596, 598 for accepting and securing the edges of thehousing halves 592, 594. The housing material may be silicone-sealedplastic, thermoplastic resin, die-cast, or sheet metal, so that theplanar optical light guide is protected. As the housings 791 and 791′and the related connector features are generally similar to that forhousing 591, the above description is equally applicable andincorporated by reference for housing 791 and 791′. Also, it is notedthat housings and connector configurations described for housings 91 and591 are applicable for each and every embodiment disclosed herein,although the opening and slot configurations may differ based on theparticular connector type and locations utilized.

Planar Optical Light Guide

As shown, the module 10 includes a planar optical light guide 20 whichhas a first surface 24 and an opposite second surface 26. The first andsecond surfaces 24, 26 extend between four side edges 28, 30, 32, 34. Inone embodiment, the optical light guide 20 base substrate ismanufactured from a silicon material.

The planar optical light guide 20 includes a base substrate layer 22that is a carrier for one or more optical pathways 36 which extendbetween the first side edge 28 and the second side edge 30. In oneembodiment, the optical pathways 36 are optical cores, surrounded by anoptical cladding layer 40 and 42. As shown schematically in FIG. 8, aplurality of optical cores 36 are shown, on top of a lower opticalcladding layer 40, and covered by an upper optical cladding layer 42.The optical cores 36 and cladding layers 40, 42 extend across the basesubstrate layer 22 and terminate at one or more of the edges (e.g. sideedges 28, 30) of the planar optical light guide 20.

The base substrate 22 material can be a glass-reinforced epoxy laminatesheet such as an FR-4 PCB (printed circuit board), silicon wafer (Sisubstrate with Si02 layer), or another suitable material. Where a PCB isused, the substrate can include copper laminated on one or both sides ofan FR-4 PCB or layered onto another type of PCB composite. Variousprocesses known in the art, such as vapor deposition and spin-coating inconjunction with a photo-thermal process, may be utilized to form theoptical cores 36 and cladding layers 40, 42. In one embodiment, theoptical pathways 36 are optical fiber cores 36 that are separatelyformed and subsequently fixed onto the base substrate 22 between thelower cladding layer 40 and upper cladding layer 42.

In an exemplary embodiment, the optical cladding layer 42 has athickness of about 100 micrometers (μm) and the optical cladding layer40 has a thickness of about 50 μm. The optical pathways or cores have asquare cross-sectional shape with a height and width of about 50 μm andare spaced (pitched) about 250 μm (center-to-center) apart from eachother. The substrate 22 utilized below the waveguide layers can be astandard FR-4 PCB having a thickness between about 0.8 μm and about 1.5μm with top and bottom copper laminate layers having a thickness of 35.6μm (1 ounce). Other configurations and thicknesses are possible withoutdeparting from the concepts presented herein.

Referring to FIG. 5, the side edges 28, 30 of the planar optical lightguide 20 can be polished or otherwise processed to permit optical signaltransmission to other planar optical light guides 20 or other fiberoptic components, such as fiber optic connectors. In one embodiment, theside edges 28, 30 are laser cut, for example by a UV laser cuttingmachine, such that polishing is not required or minimum polishing willbe required. The planar optical light guide 20 is shown in a generallyplanar state. It is to be appreciated that it need not be perfectlyplanar. It is to be appreciated that it need not be inflexible. Someflexibility is possible, if desired.

In one embodiment, the planar optical wave guide 20 may be fabricated ina three-stage process comprising creating the bottom cladding layer 40,patterning material to make the optical cores or pathways 36, andencapsulating the cores 36 with a final cladding layer 42. The materialsused can be negative-tone photoresists that can be spun and patternedusing photolithography techniques, and in particular softphotolithography using a mold fabricated with polydimethylsiloxane(PDMS). In one aspect, the wave guide 20 can be characterized as havingan inorganic-organic hybrid polymer construction wherein cladding layers40, 42 are formed to have an index of refraction of 1.5306 and theoptical cores are formed to have an index of refraction of 1.55475 witha loss of about 0.06 dB per centimeter. As configured, the planaroptical wave guide 20 has a numerical aperture (NA) of 0.273, anacceptance angle (α₀) of 15.8 degrees, and a critical angle (θ_(C)) of80 degrees.

In one step of the process, the starting substrates are conditioned withan oxygen ash followed by a thirty-minute bake on a hot plate at 200° C.The surface is then preferably spun with an adhesion promoter and bakedfor five minutes at 150° C. It is noted that it is possible to proceedwithout the adhesion promoter for some constructions. The bottomcladding layer 40 can then be spun on to the substrate 22 with aspin-coating process targeting for 50 μm. The resulting film can then begiven a three-minute soft-bake at 80° C. Subsequently, the film can behardened, for example with a blanket UV exposure, which can then befollowed by another three-minute bake at 80° C. In one embodiment, theUV exposure is performed by a Karl Suss MA6 mask aligner which is a topand bottom side contact printer used for fine lithography down to 1micron or better. Where the exposure is done in atmosphere, a thin layerof uncured liquid polymer may remain on the wafers which can be removedwith a ninety-second dip in developer. A final hard-bake can beperformed with a three-hour bake at 150° C. in a nitrogen-purged oven.

Preferably, the process of patterning the core material 36 wouldimmediately follow the hard-bake of the bottom cladding layer 40;otherwise, a hot-plate bake can be necessary to drive off moisture.Furthermore, it has been found that the adhesion of patterned waveguidepathways 36 is more reliable if the top surface of cladding layer 40 ispre-treated with an oxygen plasma. This treatment can be performed donewith a barrel asher. However, it is noted that while such a treatmentcan greatly improve the adhesion, over-etching the surface is possible,which can cause cracks and craze lines to form in the surface after thedeveloping process. In one approach, the core material 36 is appliedwith a spin-coating process targeting 50 μm thickness and given athree-minute soft-bake at 80° C. Subsequently a mask aligner and adark-field mask can be used to expose the core material 36.

Using the above described process, the photo-patterning of the waveguidestructures 36 can be a difficult part of the process as the unexposedmaterial is still wet after the soft-bake. Accordingly, with such anapproach, steps should be taken to prevent the mask from contacting thepolymer surface and the exposure should be done with a proximity mode.Exposures can be performed for ninety seconds at 12 mW/cm2 (milliwattsper centimeter squared), although lower exposures are possible.Subsequently, a post-exposure bake of a three-minute soft-bake at 80° C.can be applied. The patterns can then be developed, for example, byagitating the wafer in the developer and rinsing with isopropyl alcohol.Once again, a final hard-bake can be performed with a three-hour bake at150° C. in a nitrogen-purged oven.

It is noted that top cladding layer 42 must sufficiently encapsulate thecore 36 with enough thickness to prevent loss from the waveguide.Although such a structure can be produced that accomplishes this in onestep, doing so requires a low spin-speed which reduces the thicknesscontrol. The slower spin-speed also increases the difficulty in keepingbubbles in the resist from getting hung up on the topology of thewaveguides. Accordingly, the process can be easier to control when thetop cladding is produced in two steps; each step consisting of the samecycle of spin-coat, soft-bake, exposure, post-expose bake and hard-bakedescribed above. In one embodiment, the final cladding layer 40 would betargeted for a 50 μm thickness over the patterned core for a totalthickness of 100 μm.

Edge Connectors and Assembly

As shown, module 10 includes a plurality of edge connectors 50, in theform of fiber optic adapters. Each connector 50 connects to one or moreof the optical pathways 36. As shown, the optical waveguide module 10also includes a connection arrangement for connecting LC connectors 50to LC connectors 50. As will be described below, various alternativearrangements can be provided for the waveguide modules 10 for connectingother connector formats, or connecting one or more modules together.Module 10 shows interconnections between duplex LC connectors 50 toduplex LC connectors 50. Alternatively, the LC connectors 50 can bemanufactured as a single block of any desired number of ports.

As most easily seen at FIG. 7, each edge connector 50 includes anadapter port 52 for receiving a fiber optic connector 12, 16. Eachadapter port 52 includes an internal passageway 54 configured to receivea ferrule 13, 17 of the optical connector 12, 16 to allow the ferrule13, 17 to be placed in optical communication with the opticalpassageways 36 of the planar waveguide 20. The edge connector 50 canalso be provided with a catch 56 for engaging and retaining a latchingmechanism 14, 18 of the optical connector 12, 16.

Still referring to FIG. 7, each edge connector 50 is further shown asbeing provided with an alignment slot 60 opposite the adapter port 52.The alignment slot 60 is for providing alignment in a direction Zbetween the optical waveguide 20 and the connector 50 such that theferrule 13, 17 will be sufficiently aligned with an optical pathway 36in the direction Z. The direction Z is generally orthogonal to the planedefined by the first and second surfaces 24, 26 of the optical lightguide 20. As configured, the alignment slot 60 is formed by a firstsidewall 62, a second sidewall 64, and a base portion 66 extendingbetween the first and second sidewalls 62, 64. When the connector 50 isinstalled on a side edge (e.g. side edge 28 or 30), the first sidewall62 is adjacent to and extends over the first planar surface 24 while thesecond sidewall 64 is adjacent to and extends over the second planarsurface 26. The spacing between the sidewalls 62, 64 is generally equalto the total thickness of the optical waveguide 20 which ensures properalignment in direction Z of the adapter port 52, and thereby ferrules13, 17 relative to the ends of the optical passageways 36.

Referring to FIG. 5, the planar optical light guide 20 is shown ashaving a plurality of alignment notches 38 at the first and second sideedges 28, 30. Each of the alignment notches 38 are for providingalignment in a direction X with a corresponding protrusion 68 providedon the connector 50. Direction X is generally parallel to the length ofthe side edges 28, 30. As shown, each connector 60 is provided with twoprotrusions 68, each of which engages a corresponding notch 38 on eitherside of an optical pathway 36. As shown, a notch 38 is provided on eachside of the optical pathway 36. Accordingly, the notches 38 andprotrusions 68 index the connector 50 to the optical waveguide 20 in adirection X to ensure that the adapter port 52, and thus ferrules 13,17, is properly aligned with the ends of the optical passageways 36. Itis noted that each connector 50 may be provided with only one notch 68or more than two notches 68, as desired.

It is also noted that the depth of the notches 38 and the length of theprotrusions 68 can be configured to provide a stop position forinsertion of the connector 50 onto the optical waveguide 20 such thatthe edge connector has minimum end separation in a direction Y. Manytypical fiber optic connectors, such as connectors 12, 16, have ferrules13, 17 that are spring loaded to ensure that the ends of the ferrules13, 17 are in physical contact with another optical transmission devicesuch that no loss in efficiency or optical power loss results throughunduly large air gaps or the like. As the edges 28, 30 of the opticallight guide 20 are generally rigid, it is desirable to minimize opticalend separation of the edge connector 50 on the optical waveguide 20 inthe Y direction such that a spring loaded ferrule 13, 17 can operatewithin its own range of motion to engage with the optical pathway 36 atthe edges 28, 30 of the optical light guide 20. The Y direction isgenerally parallel to the length of the side edges 32, 34. The locationof the alignment slot base 66 can also be selected to properly positionthe connector 50 relative to the edges 28, 30 in the Y direction.

Referring to FIG. 6, optical waveguide end face protection is providedin the form of an index matching film 70. The index matching film 70protects the optical pathway 36 ends at the edges 28, 30 from theinsertion and impact forces from receiving optical connector 12, 16.This helps to prevent damage to the optical pathway ends to ensure dataintegrity and to minimize the occurrence of errors, link failures, andoptical power degradation. As shown, the index matching film 70 isapplied at least to the side edges 28, 30. The index matching film 70may also be formed along waveguide first surface 24 and the secondsurface 26 adjacent to the side edges 28, 30 to provide betterattachment and durability of the film 70. In such an application, theconnector slot sidewalls 62, 64 extend over the index matching film 70to help hold film 70 in position for assembly purposes.

Another way to prevent optical waveguide end face damage from theinsertion and impact forces from receiving an optical plug is to providea physical contact distance between waveguide side edges 28, 30 andferrule 13, 17 within the optical coupling limits. One embodiment willhave a physical contact feature which engages the optical connector 12,16 and prevents physical contact between the ferrule 13, 17 end face andthe waveguide side edges 28, 30. In one embodiment, the opticalwaveguide side edges 28, 30 are recessed back from the physical contactinterface area between the optical plug ferrule 13, 17 and opticalwaveguide side edges 28, 30. The resulting gap or distance between theoptical waveguide end face and the optical plug end face can be an airgap or filled with an index matching gel.

In order to secure the connectors 50 to the optical light guide 20, anadhesive may be applied at the interface of the alignment slot 60 andthe first and second planar surfaces 24, 26 of the optical light guide20. In one embodiment, the adhesive is an epoxy adhesive.

Referring to FIGS. 9-12, a second embodiment of an optical waveguidemodule 110 is presented. As many of the concepts and features aresimilar to the first embodiment shown in FIGS. 1-8, the description forthe first embodiment is hereby incorporated by reference for the secondembodiment. Where like or similar features or elements are shown, thesame reference numbers will be used where possible (e.g. referencenumber 150 instead of reference number 50 for the edge connector). Thefollowing description for the second embodiment will be limitedprimarily to the differences between the first and second embodiments.

The primary difference of the second embodiment is that MPO type edgeconnectors 150 are shown instead of LC duplex type connectors 50. Atypical MPO type connector 112, 116 has twelve fiber optic connections.Accordingly, the planar optical light guide 120 has significantly moreoptical pathways 136 (e.g. 36 optical pathways with three MPO connectorson each side) than that shown for the first embodiment 10.

As shown, the connectors 150 have an adapter port 152 and a catchmechanism 156 for receiving and retaining an MPO type connector.Referring to FIGS. 10 and 11, each connector 150 has an alignment slot160 having a first sidewall 162, a second sidewall 164, and a baseportion 166 extending between the first and second sidewalls 162, 164.The first and second sidewalls 162, 164 engage with the first and secondplanar surfaces 124, 126 of the optical light guide 120, respectively.Each connector 150 is also shown as having a pair of protrusions 168that interface with corresponding notches 138 in the planar opticallight guide 120. Accordingly, the connector 150 and planar optical lightguide 120 have features that align the adapter port 152 in the X, Y, andZ directions in generally the same manner as for the first embodiment.

Referring to FIGS. 13-17, a third embodiment of an optical waveguidemodule 210 is shown. As many of the concepts and features are similar tothe first and second embodiments shown in FIGS. 1-12, the descriptionfor the first and second embodiments are hereby incorporated byreference for the third embodiment. Where like or similar features orelements are shown, the same reference numbers will be used wherepossible (e.g. reference number 250 instead of reference number 50 forthe edge connector). The following description for the third embodimentwill be limited primarily to the differences between this embodiment andpreviously described embodiments.

The primary difference for the third embodiment is that an edgeconnector 250 is provided that allows two planar optical light guides220 a, 220 b to be connected together. As such, edge connector 250enables a degree of platform modularity in that preassembled planaroptical light guides having any number of different connector types andarrangements can be connected together to create an even larger numberand variety of waveguide module 210 configurations.

As shown, the edge connector 250 joins the side edges 228 of two opticallight guides 220 a, 220 b such that one or more first fiber opticconnectors 212 can be placed in optical communication with one or moresecond fiber optic connectors 216. Referring to FIG. 15, it can beobserved that the first side edges 228 are adjacent to each other whenthe optical light guides 220 a, 220 b are joined by connectors 250. Anindex matching film or gel may be applied to the first side edges 228for protection and prevention of signal power loss.

Referring to FIGS. 16 and 17, the edge connector 250 is shown as havinga first alignment slot 260 a and a second alignment slot 260 b oppositethe first alignment slot 260 a. The first alignment slot 260 a has afirst sidewall 262 a and a second sidewall 264 a that engage with thefirst and second planar surfaces 224, 226 of the optical light guides220, respectively. The second alignment slot 260 b has a first sidewall262 b and a second sidewall 264 b that engage with the first and secondplanar surfaces 224, 226 of the optical light guide 220, respectively.As with other described embodiments, the alignment slots 260 a, 260 bensure proper alignment between the optical pathways 236 of the lightguides 220 a, 220 b in the Z direction.

The edge connector 250 is also provided with a central protrusion 268 aand a pair of side protrusions 268 b. The central protrusion engageswith notches 239 in the light guide 220 a, 220 b while the sideprotrusions 268 b engage with notches 238 in the light guide 220 a, 220b. In the embodiment shown, notches 239 are larger than the notches 238,although variations are possible. The notches and protrusions cooperateto provide alignment of the optical pathways 236 of each light guide 220a, 220 b in the X direction. Likewise, the length of the notches andprotrusions can be selected to ensure a desired relative position alongdirection Y between the side edges 228 of the light guides 220 a, 220 b.

Referring to FIGS. 18-19, a fourth embodiment of an optical waveguidemodule 310 is presented. As many of the concepts and features aresimilar to the first and second embodiments shown in FIGS. 1-12, thedescription for the first and second embodiments are hereby incorporatedby reference for the fourth embodiment. Where like or similar featuresor elements are shown, the same reference numbers will be used wherepossible (e.g. reference number 350 instead of reference number 50 forthe edge connector). The following description for the fourth embodimentwill be limited primarily to the differences between this embodiment andpreviously described embodiments.

The primary difference for the fourth embodiment is that the opticalwaveguide module 310 is provided as a distribution or furcation modulein which a single side edge connector 350 a distributes fiber opticpathways to a plurality of side edge connectors 350 b, rather than therebeing a one-to-one relationship of oppositely positioned side edgeconnectors 50 or 150. More specifically, the fourth embodiment 310 showsa single side edge connector 350 a having an adapter port for an MPOtype fiber optic connector 312 from which optical pathways 336 aredistributed across the optical light guide 320 to four side edgeconnectors having duplex adapter ports for LC type connectors 316.

It is noted that a typical MPO connector generally carries twelveoptical fiber connections, and therefore the embodiment shown does notuse four of the connections provided by the MPO connector. However, itis to be understood that optical waveguide module 310 could beconfigured with a sufficient number of LC type, or other types of sideedge connectors 350 b to utilize all or fewer of the availableconnections provided by the MPO type side edge connector 350 a, as shownin later discussed embodiments.

As shown, the side edge connector 350 a and its engagement with theplanar optical waveguide module 320 is the same as that for connector150, and therefore will not be discussed further. Likewise, the sideedge connectors 350 b and their engagement with planar optical lightguide 320 are the same as that for connector 50, and also do not need tobe further discussed. However, the planar optical light guide 320differs in that the optical pathways 336 are not provided in a straightline, as is the case for waveguides 20, 120, and 220. Instead, theoptical pathways extend from a central location at the first side edge328 and bend radially outwards to be further spaced apart at the secondside edge 330. It is noted, because the dimensions and configuration ofthe optical pathways 336 can be precisely manufactured, the distancebetween the first and second side edges 328 and 330 can be significantlyreduced, as compared to other types of optical furcation means.Referring to FIG. 20, a configuration is shown in which two opticalwaveguide modules 310 are connected to each other via a cable 313 havingMPO type connectors 312 at each end.

Referring to FIGS. 21-31, a fifth embodiment of an optical waveguidemodule 410 is presented. As many of the concepts and features aresimilar to the previous embodiments shown in FIGS. 1-20, the descriptionfor the previous embodiments are hereby incorporated by reference forthe fifth embodiment. Where like or similar features or elements areshown, the same reference numbers will be used where possible (e.g.reference number 450 instead of reference number 50 for the edgeconnector). The following description for the fourth embodiment will belimited primarily to the differences between this embodiment andpreviously described embodiments.

As shown, the optical waveguide module 410 includes a planar opticallight guide 420 having features similar to that shown for the firstembodiment 20 wherein the light guide 420 extends between a first sideedge 428 and a second side edge 430 with a plurality of notches 438being provided at each edge. The edge connectors 450 are shown as havingLC duplex adapter ports 452, although other connector types may be used.However, the edge connectors 450 are different from previous embodimentsin that the edge connectors 450 are provided with a two-piece designwherein a sleeve 472 is inserted into a cavity 474 of a body 484 of theedge connector 450.

As can be most easily seen at FIGS. 28-31, each sleeve 472 is providedwith an internal passageway 473 extending into an alignment slot 460 anda pair of alignment protrusions 468 within the slot 460. As withpreviously discussed embodiments, the slot 460 sidewalls 462, 464 andthe protrusions 468 engage with the first and second planar surfaces424, 426 and the notches 438 of the optical light guide 420 to align thesleeve 472 in the X, Y, and Z directions. As shown, the protrusions 468have rounded ends to enable easier initial insertion of the protrusions468 into the notches 438.

As shown, the sleeve 472 has a first portion 476 having a slot 460 withfirst and second sidewalls 462, 464. As most easily seen at FIG. 30, thesidewalls 462, 464 are provided with a chamfer type cut at their ends toenable easier initial insertion of the optical light guide 420 into theslot 460. The sleeve 472 also has a second portion 478 that has asmaller outside dimension than the first portion 476 such that ashoulder 480 is formed. As can be seen at FIG. 27, the shoulder 480 canprovide a position stop for the sleeve 472 against a corresponding stopsurface 486 on the connector body 484. When assembled, the sleeve firstportion 476 fits tightly with the connector body cavity 474 such thatadequate alignment between the internal passageway 473 and the adapterport 452 is maintained. To allow the connector body 484 to pass over theoptical light guide surfaces 424, 426, an enlarged slot 488 is providedthat does not come into contact with the optical light guide 420.However, slot 488 may be provided to tightly fit against the opticallight guide first and second surfaces 424, 426 to further aid inalignment.

In one embodiment, the sleeve 472 is provided with an aperture 482through which an adhesive, such as an epoxy, can be applied to securethe sleeve 472 to the optical light guide 420 and/or the edge connectorbody 484. As shown at FIGS. 26 and 27, an optional index matching film470 may be provided.

Referring to FIGS. 32-42, a sixth embodiment of an optical waveguidemodule 510 is presented. As many of the concepts and features aresimilar to the previous embodiments shown in FIGS. 1-31, the descriptionfor the previous embodiments are hereby incorporated by reference forthe sixth embodiment. Where like or similar features or elements areshown, the same reference numbers will be used where possible (e.g.reference number 550 instead of reference number 50 for the edgeconnector). The following description for the sixth embodiment will belimited primarily to the differences between this embodiment andpreviously described embodiments.

The sixth embodiment 510 is similar to the fifth embodiment, in that aplurality of two-piece type connectors is used for the optical lightguide. The sixth embodiment 510 is also similar to the fourthembodiment, in that an optical waveguide module 510 is provided as adistribution or furcation module in which a single side edge connector550 a distributes fiber optic pathways to a plurality of side edgeconnectors 550 b. As with the fourth embodiment, the sixth embodimentshows a single side edge connector 550 a having an adapter port for anMPO type fiber optic connector 512 from which optical pathways 536 aredistributed across the optical light guide 520, and in this case, to sixside edge connectors 550 b having duplex adapter ports for LC typeconnectors 516. However, the sixth embodiment is different in that atwo-piece connector 550 a with an MPO type adapter port is utilized, andin that the side edge connectors 550 b are provided on three side edges530, 532, 534 of the optical light guide 520. As the connectors 550 bhave already been discussed in detail for the fifth embodiment, theywill not be discussed further.

As can be most easily seen at FIGS. 32-42, each sleeve 572 a is providedwith an internal passageway 573 extending into an alignment slot 560 anda pair of alignment walls 568 within the slot 560. It is noted thatoptical light guide 520 includes a protrusion 538 that engages with thewalls 568 to align the sleeve 572 a in the X direction and in the Ydirection. As with previously discussed embodiments, the slot 560sidewalls 562, 564 engage with the first and second planar surfaces 524,526 of the optical light guide 520 to align the sleeve 572 a in the Zdirection. As shown, the alignment walls 568 have rounded ends to enableeasier initial insertion of the sleeve 572 a onto the protrusion 538. Itis noted, that although the protrusion 538 and alignment wall 568configuration is described for an MPO type connector, this configurationcould also be used for other types of connectors, such as LC typeconnectors.

As shown, the sleeve 572 a has a first portion 576 having a slot 560with first and second sidewalls 562, 564. As most easily seen at FIG.41, the sidewalls 562, 564 are provided with a chamfer type cut at theirends to enable easier initial insertion of the optical light guide 520into the slot 560. The sleeve 572 a also has a second portion 578 thathas a smaller outside dimension than the first portion 576 such that ashoulder 580 is formed. In one embodiment, the shoulder 580 can providea position stop for the sleeve 572 a against a corresponding stopsurface on the connector body 584. When assembled, the sleeve firstportion 576 fits tightly with the connector body cavity 574 such thatadequate alignment between the internal passageway 573 and the adapterport 552 is maintained. To allow the connector body 584 to pass over theoptical light guide surfaces 524, 526, a slot 588 is provided that canbe configured to not come into contact with the optical light guide 520or configured to contact the first and second surfaces 524, 526 toadditionally aid in alignment.

In one embodiment, the sleeve 572 a is provided with apertures 582through which an adhesive, such as an epoxy, can be applied to securethe sleeve 572 a to the optical light guide 520 and/or the edgeconnector body 584. The sleeve 572 a is also shown as being providedwith receptacles 590 that are configured for receiving correspondingalignment pins on the connector 512. An optional index matching film 570may be also provided on the side edges 528, 530, 532, and 534.

Referring to FIG. 43, a seventh embodiment of an optical waveguidemodule 610 is presented. As many of the concepts and features aresimilar to the previous embodiments shown in FIGS. 1-42, the descriptionfor the previous embodiments are hereby incorporated by reference forthe sixth embodiment. Where like or similar features or elements areshown, the same reference numbers will be used where possible (e.g.reference number 650 instead of reference number 50 for the edgeconnector).

The seventh embodiment 610 is similar to the sixth embodiment 510, inthat a plurality of two-piece type connectors is used for the opticallight guide in a furcation application. The seventh embodiment 610 isalso similar to the fourth embodiment in that all of the side edgeconnectors 650 a, 650 b are on opposite sides of the optical light guide620. As with the sixth embodiment, the seventh embodiment shows a singleside edge connector 650 a having an adapter port for an MPO type fiberoptic connector 612 from which optical pathways 636 are distributedacross the optical light guide 620, and in this case, to six oppositelypositioned side edge connectors 650 b having duplex adapter ports for LCtype connectors 616. As the connectors 650 a, 650 b have already beendiscussed in detail for the fifth and sixth embodiments, they will notbe discussed further.

Referring to FIGS. 46-67, an eighth embodiment of an optical waveguidemodule 710 is presented. As many of the concepts and features aresimilar to the previous embodiments shown in FIGS. 1-45, the descriptionfor the previous embodiments are hereby incorporated by reference forthe eighth embodiment. Where like or similar features or elements areshown, the same reference numbers will be used where possible (e.g.reference number 750 instead of reference number 50 for the edgeconnector). The following description for the eighth embodiment will belimited primarily to the differences between this embodiment andpreviously described embodiments.

The eighth embodiment 710 is similar to the fifth through seventhembodiments, in that a plurality of two-piece type connectors is used inconjunction with an optical light guide 720. The eighth embodiment 710is also similar to the sixth embodiment in that an optical waveguidemodule 710 is provided as a distribution or furcation module in which asingle side edge connector 750 a distributes fiber optic pathways to aplurality of side edge connectors 750 b. As with the sixth embodiment,the eighth embodiment shows a single side edge connector 750 a having anadapter port for an MPO type fiber optic connector (e.g. 512) from whichoptical pathways 736 are distributed across the optical light guide 720,and in this case, to six side edge connectors 750 b having duplexadapter ports for LC type connectors (e.g. 516). However, the eighthembodiment is different in that the two-piece MPO type adapter portconnector 750 a utilizes a sleeve 772 a that engages with only one side724 and an edge 728 of the optical light guide 720 instead of a slotthat engages both sides (e.g. 24, 26) and the edge (e.g. 28) of thelight guide 720. Similarly, the eighth embodiment is also different inthat the LP type adapter port connector 750 b utilizes a sleeve 772 bthat engages with only one side 724 and one edge 730, 732 or 734 of theoptical light guide 720 instead of a slot that engages both sides (e.g.24, 26) and an edge (e.g. 28) of the light guide 720. Accordingly, eachedge connector 750 a and 750 b continues to have a slot 788 that extendsacross the sides 724 and 726 of the optical light guide 720, but inwhich the cavity 774 is only provided adjacent the side 724 of the lightguide 720 at which the optical pathways 736 are provided.

As can be most easily seen at FIGS. 54-60, each sleeve 772 b is providedwith an internal passageway 773 extending into an alignment channel 760with a pair of alignment protrusions 768 adjacent the channel 760. Asshown, the channel is bounded by sidewalls 762 and planar surface 769extending in a perpendicular direction from the sidewalls 762. As shown,the sleeve 772 b has a first portion 776 including the channel 760 withthe sidewalls 762. The sleeve 772 b also has a second portion 778through which passageway 773 extends and which forms a shoulder 780. Theshoulder 780 can provide a position stop for the sleeve 772 b against acorresponding stop surface on the connector body 750 b, as shown forother embodiments. When assembled, the sleeve first portion 776 fitstightly with the connector body cavity 774 such that adequate alignmentbetween the internal passageway 473 and the adapter port is maintained.To allow the connector 750 b to pass over the optical light guidesurfaces 724, 726, an enlarged slot 788 is provided that does not comeinto contact with the optical light guide 720. However, slot 788 may beprovided to tightly fit against the optical light guide first and secondsurfaces 724, 726 to further aid in alignment. As shown for otherembodiments, the sleeve 772 b may be provided with an aperture throughwhich an adhesive, such as an epoxy, can be applied to secure the sleeve772 b to the optical light guide 720 and/or the edge connector body 750b. An optional index matching film may also be provided.

Referring to FIGS. 61-67, sleeve 772 a is shown in greater detail. Aspresented, each sleeve 772 a is provided with a channel 773 configuredto receive a tab portion 739 adjacent recess portions 741 of the opticallight guide 720. The sleeve 772 a is also shown as being provided withreceptacles 790 that are configured for receiving correspondingalignment pins on the connector (e.g. connector 512). The sleeve 772 ais also provided with alignment channels 760 with a pair of alignmentprotrusions 768 adjacent the channels 760. As shown, the channels 760are bounded by sidewalls 762 and planar surfaces 769 extending in aperpendicular direction from the sidewalls 762. As shown, the sleeve 772a has a first portion 776 including the channels 760 with the sidewalls762. The sleeve 772 a also has a second portion 778 through whichchannel 773 extends and which forms a shoulder 780. The shoulder 780 canprovide a position stop for the sleeve 772 a against a correspondingstop surface on the connector body 750 a, as shown for otherembodiments. When assembled, the sleeve first portion 776 fits tightlywith the connector body cavity 774 such that adequate alignment betweenthe channel 773 and the adapter port is maintained. To allow theconnector 750 a to pass over the optical light guide surfaces 724, 726,an enlarged slot 788 is provided that does not come into contact withthe optical light guide 720. However, slot 788 may be provided totightly fit against the optical light guide first and second surfaces724, 726 to further aid in alignment. As shown for other embodiments,the sleeve 772 a may be provided with an aperture through which anadhesive, such as an epoxy, can be applied to secure the sleeve 772 a tothe optical light guide 720 and/or the edge connector body 750 a. Anoptional index matching film may also be provided.

In one aspect, the planar surface 769 of each of the sleeves 772 a, 772b engages with the side edge 728, 730, 732, or 734 of the optical lightguide 720 to align the position of the sleeve 772 a, 772 b in the Ydirection while the sidewalls 762 engage with the first planar surface724 of the optical light guide 720 to align the sleeve in the Zdirection. As with other embodiments, the protrusions 768 engage withnotches 738 of the optical light guide 720 to align the sleeve 772 a,772 b in the X direction. As shown, the protrusions 768 have roundedends to enable easier initial insertion of the protrusions 768 into thenotches 738. Because the sleeve 772 a, 722 b is provided with sidewalls762 instead of a slot, the sleeve 772 can be installed onto the firstsurface 724 of the optical light guide 720 in a downward directioninstead of sliding the sleeve onto the optical light guide 720 from oneof the side edges 728, 730, 732, 734. Furthermore, the use of sidewalls762 instead of a slot allow the sleeve 772 a, 772 b to be positionedonto the optical light guide 720 without reliance on the exact thicknessof the optical light guide 720 for proper positioning of the sleeve 772a, 772 b in the Z direction.

In contrast to other embodiments, and as most easily seen at FIGS. 52and 53, the optical light guide 720 can be provided with notches 738that extend only partially through the thickness of the optical lightguide 720 at a first depth d from the first surface 724. In oneembodiment, the notches 738 have a depth d that is the same as thethickness of the cladding layer 742, while in another embodiment, thenotches 738 have a depth d that is equal to the thickness of thecladding layers 740 and 742. In another embodiment, the notches 738extend through the cladding layers 740, 742 and into the base substratelayer 722. Of course, the notches 738 may also extend all of the waythrough the cladding layers 740, 742 and the base substrate layer 722 aswith the other shown embodiments. Likewise, the other shown embodimentsmay be provided with notches that do not extend completely through theoptical light guide as well. Where a partial depth notch 738 isprovided, the protrusions 768 can be provided with a correspondingheight h that is equal to or less than the depth d of the notch 738 suchthat the sidewalls 762 can engage with the first surface 724 of theoptical light guide 720.

Because the sleeves 772 a and/or 772 b are provided with open sidewalls762 and mounted in a downward direction onto the optical light guide720, it is also possible to provide the notches 738 with shapes otherthan the longitudinal opening that would be normally associated with aslotted sleeve. By using a shape or shapes for the notch 738 that alsoextend in the X direction on the optical light guide 720 in conjunctionwith similarly shaped protrusions 768, the sleeves 772 a and/or 772 bcan be fixed in both the X and the Y directions by the notch 738engaging with the protrusion 768. Non-limiting examples of shapes thatextend in the X and Y directions are intersecting orthogonal slots, asshown at FIG. 73, polygonal shapes (e.g. a circle, square, rectangle,etc.), and combinations of shapes having dimensions that extend in the Xand Y direction, as shown at FIG. 74.

In one configuration, each sleeve 772 a and/or 772 b is aligned andmounted to the optical light guide 720 in a temporary fixture. In thetemporary fixture, the sleeves 772 a and/or 772 b can be permanentlyattached to the optical light guide 720, for example with epoxy.

Referring to FIGS. 68-72, a ninth embodiment of an optical waveguidemodule 710′ is presented that is generally similar to the eighthembodiment 710. As many of the concepts and features are similar to theprevious embodiments shown in FIGS. 1-67, the description for theprevious embodiments are hereby incorporated by reference for the ninthembodiment. Where like or similar features or elements are shown, thesame reference numbers will be used where possible (e.g. referencenumber 750 instead of reference number 50 for the edge connector).

The ninth embodiment 710′ is similar to the eighth embodiment 710, inthat a plurality of two-piece type connectors with non-slotted sleevesis used for the optical light guide. The ninth embodiment 710′ is alsosimilar to the fifth embodiment in that all of the side edge connectorsare on opposite sides of the optical light guide 720′. For the ninthembodiment, a plurality of LC-simplex type side edge connectors 750 b′are provided at a first side edge 728′ of the optical light guide 720′while a combination of LC-simplex type side edge connectors 750 b′ andLC-duplex type side edge connectors 750 b are provide at a secondopposite side edge 730′ of the optical light guide 720′. As shown, fiveLC-simplex type edge connectors 750 b′ are provided on the first sideedge for a total of five optical pathway connections. The second sideedge includes three LC-simplex type edge connectors 750 b′ and twoLC-duplex type side edge connectors 750 b for a total of seven opticalpathway connections. As most easily seen at FIG. 72, the optical lightguide 720′ for this embodiment is provided with three linear opticalpathways 736 extending between the first and second side edges 728′,730′ and between oppositely positioned connectors 750 b′. The opticallight guide 720′ is also provided with two split pathways 736′ thatextend from the first side edge 728′ and from a connector 750 b′ whichsplit into a first pathway 736 a and a second pathway 736 b beforereaching the second side edge 730′ and a connector 750 b. As theconnectors 750 a, 750 b have already been discussed in detail they willnot be discussed further for this embodiment.

In one embodiment, the above described connectors and sleeves are formedfrom a thermoplastic resin material, for example polyetherimide (PEI)thermoplastic resin. In one embodiment, the thermoplastic resin materialis formed into the connectors and sleeves through the use of a micromolding process which allows for very high tolerances to be achieved.

The various embodiments described above describe a platform that willhave minimum components and assembly processes with short lead-time andlow cost for final module product. The embodiments can also be used foroptical modules such as signal splitters (OLS/GPON), monitor testing(TAP), wavelength division multiplexing (WDM), transceivers for opticalto electrical converters, backplane interconnects, physical layermanagement, and MEMS integration for optical cross-connects.Furthermore, as the side edge connectors are configured with adapterports that receive standard fiber optic connectors, the fiber opticconnectors and side edge connectors are easily connected anddisconnected from each other in a repeatable fashion without the needfor time consuming optical alignment procedures. Furthermore, the abovedescribed connectors and alignment features provide for fiber opticconnectivity between the connectors and cores/pathways that satisfiesinternational standard IEC-61754-20 (for LC connectors) and standardIEC-61754-7 (for MPO connectors).

The various embodiments described above are provided by way ofillustration only and should not be construed to limit the claimsattached hereto. Those skilled in the art will readily recognize variousmodifications and changes that may be made without following the exampleembodiments and applications illustrated and described herein, andwithout departing from the true spirit and scope of the disclosure. Itis particularly noted that the disclosure is not limited to the discreteembodiments disclosed, as many combinations of features among andbetween the disclosed embodiments can be combined in a number of ways.

1.-13. (canceled)
 14. An optical waveguide module comprising: a. a firstoptical light guide having first and second opposite surfaces extendingbetween first and second opposite side edges, the first optical lightguide including one or more first optical pathways extending between thefirst and second side edges; b. a second optical light guide havingfirst and second opposite surfaces extending between first and secondopposite side edges, the second optical light guide including one ormore second optical pathways extending between the first and second sideedges; and c. a first edge coupler aligning the one or more firstoptical pathways of the first optical light guide with the one or moresecond optical pathways of the second optical light guide: i. the firstedge coupler having a first alignment slot and a second alignment slotopposite the first alignment slot; ii. the first alignment slotextending over the first optical light guide first and second planarsurfaces at the first side edge to align the first edge coupler with theone or more first optical pathways in a first direction; iii. the secondalignment slot extending over the second optical light guide first andsecond planar surfaces at the first side edge to align the first edgecoupler with the one or more second optical pathways in the firstdirection.
 15. The optical waveguide module of claim 14, wherein the oneor more first edge connectors each align two first optical pathways totwo second optical pathways.
 16. The optical waveguide module of claim15, wherein the one or more first edge connectors includes four edgeconnectors.
 17. The optical waveguide module of claim 14, furthercomprising: a. one or more first edge connectors, each first edgeconnector having a first adapter port and a first alignment slotopposite the first adapter port, the first alignment slot extending overthe first optical light guide first and second planar surfaces at thesecond side edge to align the first adapter port with the one or morefirst optical pathways in the first direction; and b. one or more secondedge connectors, each second edge connector having a second adapter portand a second alignment slot opposite the second adapter port, the secondalignment slot extending over the second optical light guide first andsecond planar surfaces at the second side edge to align the secondadapter port with the one or more second optical pathways in the firstdirection.
 18. The optical waveguide module of claim 17, wherein thefirst and second adapter ports are LC duplex type adapter ports.
 19. Anoptical waveguide module comprising: a. an optical light guide havingopposite first and second planar surfaces extending between a first sideedge and a second side edge, the optical light guide including one ormore optical pathways extending between the first and second side edges;b. one or more first edge connectors, each first edge connector having afirst sleeve received within a cavity of a first body, the first bodyhaving a first adapter port, the first sleeve having a first alignmentslot opposite the first adapter port, the first alignment slot extendingover the optical light guide first and second planar surfaces at thefirst side edge to align the first adapter port with the one or moreoptical pathways in a first direction; and c. one or more second edgeconnectors, each second edge connector having a second sleeve receivedwithin a cavity of a second body, the second body having a secondadapter port, the second sleeve having a second alignment slot oppositethe second adapter port, the first alignment slot extending over theoptical light guide first and second planar surfaces at the second sideedge to align the second adapter port with the one or more opticalpathways in the first direction.
 20. The optical waveguide module ofclaim 19, wherein the optical light guide includes a plurality ofnotches at the first and second side edges and the one or more first andsecond sleeves each include an alignment protrusion engaging with one ofthe plurality of notches to align the first and second adapter portswith the one or more optical pathways in a second direction that isorthogonal to the first direction.
 21. The optical waveguide module ofclaim 19, wherein the one or more first edge connectors includes aplurality of first edge connectors.
 22. The optical waveguide module ofclaim 19, wherein the first adapter port of the one or more first edgeconnectors is an LC adapter port.
 23. The optical waveguide module ofclaim 22, wherein the first adapter port of the one or more first edgeconnectors is a duplex LC adapter port.
 24. The optical waveguide moduleof claim 19, wherein the first adapter port of the one or more firstedge connectors is an MPO adapter port.
 25. The optical waveguide moduleof claim 19, wherein the optical waveguide module includes a pluralityof first edge connectors and a plurality of second edge connectors. 26.The optical waveguide module of claim 25, wherein the first adapterports of the first edge connectors are LC duplex adapter ports and thesecond adapter ports of the second edge connectors are LC duplex adapterports.
 27. The optical waveguide module of claim 25, wherein the firstadapter ports of the first edge connectors are MPO adapter ports and thesecond adapter ports of the second edge connectors are MPO adapterports.
 28. The optical waveguide module of claim 19, wherein the opticalwaveguide module includes a single first edge connector and a pluralityof second edge connectors, the adapter port of the first edge connectorbeing an MPO adapter port, the adapter ports of the second edgeconnector being LC duplex adapter ports.
 29. The optical waveguidemodule of claim 28, wherein the first side edge and the second side edgeare opposite each other.
 30. The optical waveguide module of claim 19,further comprising: a. one or more third edge connectors, each thirdedge connector having a third sleeve received within a cavity of a thirdbody, the third body having a third adapter port, the third sleevehaving a third alignment slot opposite the third adapter port, the thirdalignment slot extending over the optical light guide first and secondplanar surfaces at a third side edge to align the third adapter portwith the one or more optical pathways in the first direction; and b. oneor more fourth edge connectors, each fourth edge connector having afourth sleeve received within a cavity of a fourth body, the fourth bodyhaving a fourth adapter port, the fourth sleeve having a fourthalignment slot opposite the fourth adapter port, the fourth alignmentslot extending over the optical light guide first and second planarsurfaces at a fourth side edge to align the fourth adapter port with theone or more optical pathways in the first direction.
 31. The opticalwaveguide module of claim 30, wherein the optical waveguide moduleincludes a single first edge connector and a plurality of second, third,and fourth edge connectors, the adapter port of the first edge connectorbeing an MPO adapter port, the adapter ports of the plurality of second,third, and fourth edge connectors being LC duplex adapter ports.
 32. Theoptical waveguide module of claim 19, wherein the first body and thesecond body each include an alignment slot that engage the first andsecond planar surfaces of the optical light guide.